Method of cutting using silicon carbide whisker reinforced ceramic cutting tools

Abstract

Cutting tools are disclosed which are comprised of composite bodies comprising a ceramic matrix reinforced by ceramic whiskers. The ceramic matrix may be alumina or silicon nitride, and may contain toughening components. The whiskers are preferably silicon carbide, but may be other known ceramic whiskers. Whisker content in the composite is 2-40%, with higher contents generally used for tools when the expected service involves interrupted cutting and lower contents generally used for continuous cutting tools.

What is claimed is: 
     
       1. In a method of cutting metal wherein a cutting tool is brought into contact with a metal workpiece and the cutting tool and metal workpiece move relative to each other whereby metal is removed by the cutting tool from the metal workpiece, the improvement comprising using a sintered composite cutting tool having a matrix consisting essentially of alumina and 2-40 volume percent silicon carbide whiskers distributed therethrough. 
     
     
       2. The method of claim 1 in which the metal is removed substantially continuously. 
     
     
       3. The method of claim 1 wherein said metal cutting is selected from shaping, planing, milling, facing, broaching, grinding, sawing, turning, boring, drilling and reaming. 
     
     
       4. The method of claim 1 wherein said composite consists essentially of 65-80 volume percent alumina and 20-35 volume percent whiskers. 
     
     
       5. The method of claim 1 wherein said composite consists essentially of 88-98 volume percent alumina and 2-12 volume percent whiskers.